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Design of Shaft Is an Important Tool in Mercerization Machine
J. H. Mokade1, N. P. Awate2
1,2
Department of Mechanical Engineering, G. H. Raisoni College of Engineering, Nagpur Maharashtra, India.
ABSTRACT: Mercerizing is one of part of wet processing technology. It is the special type of
treatment. Mercerization is done to get some special properties of the textile materials. In this process,
the physical properties of the material get change. The mercerization process essentially consists of
treatment of cotton yarn in high concentration caustic soda under tension. If cotton is dipped into a
strong alkaline solution such as lithium hydroxide, caustic soda, or potassium hydroxide, the fibers will
swell and shrink. If the fibers are placed under tension while in this swollen state and then rinsed with
water, the alkali will be removed and a permanent silk-like luster will result It will be highly desirable to
introduce this process in khadi sector which will lead to considerable saving in the dying cost. The
handling of the hank is in appropriate; disarrangement of the lengths of yarn in one loop can result in
different tensions, leading to uneven mercerization due to uneven tension is an unavoidable problem in
this methods. This not only reduces productivity, but also results in many yarn-piecing defects during
production. In this process tension can be derived by using proper shaft in mercerization machine by
measuring the load required to keep the yarn or the fabric at the same length. The latter tension, being a
tension intentionally exerted during mercerization, can be considered in three stages, 1) These being
during the penetration of the alkaline solution and the swelling, during the fixing of the dimensions 2)
Temperature during the treatment, 3) Control of the tension during the different stages is important in
the supervision of the mercerizing process. In this process number of hanks are loaded on shaft and
rotated for required time. Due to caustic soda treatment, the yarn get swell and length of yarn reduced
upto 1/4th, due to continuous rotation of shaft, the load developed on shaft and shaft get bend. These
problems may be overcome by designing of optimized shaft in mercerization machine.
Keywords: Mercerization, Mercerizing Machine, caustic soda, Shaft failure, Bending, Mechanical
tension.
I. Introduction
Mercerization is the treatment of cotton with a strong caustic alkaline solution in order to improve the
luster, hand and other properties, was named after its discoverer, John Mercer, and has been in use for some
time. The process of mercerization was developed in 1856, since then it is important in the textile mill sector.
Mercerizing is one of part of wet processing technology. It is the special type of treatment. Mercerizing is done
for getting some special properties of the textile materials. In which process the physical properties of the
material change. Increased dye-uptake, dimensional stability, increased moisture regain, increased reactivity etc.
If cotton is dipped into a strong alkaline solution such as lithium hydroxide, caustic soda, or potassium
hydroxide, the fibers will swell and shrink. If the fibers are placed under tension while in this swollen state and
then rinsed with water, the alkali will be removed and a permanent silk-like structure will result. It will be
highly desirable to introduce this process in Khadi sector which will lead to considerable saving in the dying
cost. In Mercerization machine number of shaft (10-15) arranged in parallel position, these shafts are supported
by another shaft which is in parallel position at lower side. The arrangements of all shafts are star arrangement.
Initially the yarn is loaded on upper shaft then lower and again on another upper shaft, in this way the shaft
rotates continuously for 7 to 8 minute. The hank (yarn) is loaded through the shaft; each hank has a weight
around 0.7 to 1.2 kg. These hanks are dipped in caustic soda solution or alkaline sodium hydroxide solution.
Due to absorption of caustic soda solution by the yarn, chemical reaction occurs and as results the length of yarn
reduces which are turn develops the stress in shaft.
The stress developed in the shaft due to following reasons
1. Length reduction of the yarn
2. The weight of the yarn gradually increased
3. Twisting movement of the shaft due to rotation
During the course of time the bending of the shaft occurs and misalignment of shaft result which in turn has a
great adverse effect on the production line, also the misalignment damages the machine and the yarn.
| IJMER | ISSN: 2249–6645 |
www.ijmer.com
| Vol. 4 | Iss. 1 | Jan. 2014 |229|

2. Design of Shaft Is an Important Tool in Mercerization Machine
II. Purpose/Need Of Mercerizing
The main changes occurring in the alkaline treatment of cotton are:
1. Solubility in solvents is increased;
2. The length of yarn or area of cloth is reduced;
3. Tensile strength is increased;
4. Absorption of dyestuff is increased;
5. Physical compactness of either cloth or yarn is increased;
6. Water absorption is increased;
7. Reactivity with oxygen (air) is increased;
8. Reactivity of cotton at lower temperatures is increased;
9. Sodium hydroxide (caustic soda) is preferentially absorbed during the process;
10. Luster is increased;
11. Rate of oxidation causing degradation is increased;
12. Removes immature (dead) cotton;
13. Lowers dye cost (up to 40 % on certain colors).
III. Absorption Of The Alkali And Swelling
The cotton hair swells in a strong caustic soda solution, and on viewing the changes in the cross-section
that occur during the mercerization process shown in figure, the cross section, originally shaped like a squashed
circular pipe, clearly becomes oval-shaped, thus enhancing the luster. The large differences in the swelling that
occur due to the concentration of the alkaline solution are relative to the longitudinal shrinkage of the hair.
Fig no: 1Changes in the cross-section of a cotton hair during mercerization
Fig no: 2 Un Mercerized cotton
Fig no: 3 Mercerized cotton
Fig: 4 Change in length of a cotton hair when dipped in decreasing concentrations of alkaline solution (NaOH)
| IJMER | ISSN: 2249–6645 |
www.ijmer.com
| Vol. 4 | Iss. 1 | Jan. 2014 |230|

3. Design of Shaft Is an Important Tool in Mercerization Machine
Fig no: 5 Change in length of a cotton hair when dipped in increasing concentrations of alkaline solution
(NaOH)
IV. Tension After The Swelling Due To The Alkali
The tension introduced after the swelling of the yarn or the fabric is a mechanical tension exerted to
resist the force of the shrinkage of the shrunk yarn or fabric and, by stretching, it fixes the dimensions as
required. At this time, the problem in the processing is not the degree of tension required but the amount of
stretching. For the generation of a good luster, stretching to the original length before the processing is usually
the norm, but stretching beyond the original length will enhance the luster even more. However, stretching is not
often beyond the original length of the yarn or the fabric due to the mechanical difficulties and the negative
effects on hand and strength.
V. Problem Arises In Mercerization Machine
The winding or the handling of the hank is in appropriate; disarrangement of the lengths of yarn in one
loop can result in different tensions, leading to uneven mercerization, which can often result in patchy dyeing.
Uneven mercerizing due to uneven tension is an unavoidable problem in current methods of mercerization.
While in theory reduction of the amount of yarn in one hank increases the evenness of the mercerization, this
not only reduces productivity, but also results in many yarn-piecing defects during production of the weave or
knit due to inadequate yarn length. For these reasons, using optimized shaft yarn that has been hank mercerized
and then dyed for finishing into solid-color fabrics can result in a barrel effect,
Another problem in hank mercerization is that conventional rinsing after mercerization is insufficient,
and without neutralization through separate rinsing with hot water, the remaining alkali can cause problems.
While in theory there are no reasons preventing sufficient neutralization through removal of the alkali in this
method, complete treatment of batches in hank form a low efficiency, and so not used due to the cost and the
level of productivity. Thus, if treatments must be conducted separately by using proper shaft in mercerization
machine, Furthermore, handling in hank form is necessary in the scouring and bleaching which follow, as well
as in the dyeing, and there is a tendency for the quality of the yarn to deteriorate due to disarrangement of the
yarn. Finally, after drying, winding from the hank to a cone or cheese is necessary, and the effort and labor
hours needed for this are a major disadvantages. The resulting negative tension can be derived by using proper
shaft in mercerization machine measuring the load required to keep the yarn or the fabric at the same length as
that before processing, but because this tension cannot be adjusted during mercerization itself, if any
adjustments are required, measures must be taken during the design stage of the yarn or the fabric. The latter
tension, being a tension intentionally exerted during mercerization, can be considered in three stages,
A)These being during the penetration of the alkaline solution and the swelling, during the fixing of the
dimensions
B)Temperature during the treatment,
C)Control of the tension during the different stages is important in the supervision of the mercerizing process.
In this process the hanks are held on shaft. At a time numbers of hanks are loaded on shaft and rotated
automatically for required time. Due to caustic soda treatment, the yarn shrinkages and length is reduced. Due to
continuous rotation of shaft the load is developed on shaft and shaft get bend. To avoid the bending of shaft, it
has important tool to carried out design and analysis of optimized shaft mercerization machine
| IJMER | ISSN: 2249–6645 |
www.ijmer.com
| Vol. 4 | Iss. 1 | Jan. 2014 |231|

4. Design of Shaft Is an Important Tool in Mercerization Machine
VI.
Need Of Designing Of Mercerization Machine Shaft
As shaft have several types of failure from which bending Failure is have huge impact on mercerization
process. We are concentrate on bending failure for design of Mercerization machine shaft.
In the dyeing of cotton, it is well known that if caustic soda is used in vat dyes and other dyes which
use caustic soda, the dye's ability to be absorbed will decline, this tendency being especially strong in weak
alkaline vat dyes. Caustic soda has an affinity for cellulose fibers, and through routine dyeing experience, it is
well known that the removal of caustic soda through rinsing is very difficult when compared with the removal
of acid. However, within the range of concentrations of caustic soda generally used in dyeing, the properties and
form of cotton does not incur any particular effects, but if the alkaline concentration is gradually increased, they
will be affected. Due to the different effects on different yarns, which are a collection of single fibers, or on
different knits and wovens a variety of factors have complex cumulative effects, and the basic behavior of
cotton exposed to certain alkalis is difficult to ascertain accurately, but clarification has come through using
cotton hairs (single cotton fibers). Subsequently, researchers have repeatedly conducted experiments which
included quantitative measurements, but the results have lacked consistency. While the reasons for this may be
related to experimental procedure or certain errors, essentially, factors involved in the type and the maturation
process of natural macro molecules like those in cotton can result in considerable differences in the resulting
properties, structure and configuration. In addition to the variations in the responses to alkalis which result from
these factors, a precise experimental procedure is difficult to determine, and this can also be considered a factor
contributing to the difficulties.
Design and analysis of optimized shaft in machine of mercerization is to minimize the shrinkages in the
yarn, increase machining accuracy. The time and capital cost in maintenance can be reduced. The life of
machine can be increase, so repair and maintenance charges are minimize. The machine will run smoothly and
efficiently so bending of mercerization machine shaft can be avoided.
VII. Significance Of Work
By designing of optimized mercerization machine shaft can control of tension during mercerization. In
mercerization process there are two types of tension occur, one produced by the constraining force in opposition
to the swelling caused by the twisting of the yarn or the structural density of the yarn when the single fibers
which constitute the yarn or the absorb alkaline solution and swell, the other being intentionally exerted on the
yarn or fabric during mercerization. The former type of tension occurs due to the relationship between the force
of the swelling and the constraining force in opposition to it, and although not certain, as it is due to the force of
the swelling, it can be expected to design proper dimension of shaft .
The design of mercerization machine shaft will provide an apparatus for mercerizing the yarn
continuously as well as uniformly in caustic soda solution in predetermined quantity under uniform tension in
short period of time. This increases the productivity of machine. The fabric produced from mercerized yarn will
be dimensionally stable thus reducing the customer complaints of shrinkage of Khadi fabric or garments on
washing it will save more dye consumption. By further modification the machine capacity can increase.
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| IJMER | ISSN: 2249–6645 |
www.ijmer.com
| Vol. 4 | Iss. 1 | Jan. 2014 |232|